From 63.3 million tons in 2022, global polyester production has increased by 15 per cent to over 73 million tons currently.
As per a report by a non-profit organisation, RMI Institute, this growth is largely being driven by the fashion, home furnishings, and furniture industries, especially fast fashion, which raises concerns about waste and carbon emissions. A single polyester t-shirt emits 20.6 kg of CO2 over its lifecycle, and with billions sold annually in the US, the environmental impact is substantial. Brands like Nike and Patagonia are responding by incorporating recycled polyester and other eco-friendly materials.
Polyester production starts with fossil fuel-based chemicals, such as naphtha and ethane, which are transformed into PET resin, the foundation for textiles, plastic bottles, and other products. PET's carbon footprint can be double that of other plastics due to its complex manufacturing process. Reducing emissions in polyester production is challenging because of high costs, slim profit margins, and the need for major capital investments. However, creating a specialised market for low-emissions polyester could make these investments worthwhile, similar to what's been done in the sustainable aviation fuel sector.
To cut emissions, PET suppliers can transition to renewable energy sources, while chemical producers can explore innovative methods like bio-based feedstocks, carbon capture, electrification, and recycling. On their part, retailers can lead by forming buyer alliances to set clear demand and price signals for low-emission products, following the model used in sustainable aviation. Meanwhile, feedstock suppliers and chemical manufacturers will need considerable funding to update production facilities, a process that can be supported through subsidies, tax incentives, and regulatory systems like the EU’s Emissions Trading System.
Creating a market for low-emissions polyester requires standardised certifications and aligned product standards. Consumer interest and the higher profit margins of sustainable fashion suggest that this approach is viable. Moving forward, the industry would need to balance voluntary initiatives with policy measures to hit emissions targets in the rapidly expanding polyester market.
